MAKING MODERN LIVING POSSIBLE
Service Manual
Proportional Valve Group
PVG 120
powersolutions.danfoss.com
Service Manual |
PVG 120 Proportional Valve Group |
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Revision history |
Table of revisions |
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Date |
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Changed |
Rev |
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May 2014 |
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Converted to Danfoss layout – DITA CMS, major revision |
JA |
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Jan 2012 |
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Pos. 3 change |
ID |
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Feb 2011 |
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Table on page 35 changed, layout changes - all pages |
IC |
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Feb 2010 |
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Handles on drawings |
IA |
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Jan 2010 |
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Japan location |
HC |
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2 |
520L0247 • Rev JA • May 2014 |
Service Manual |
PVG 120 Proportional Valve Group |
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Contents |
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PVG 120 service parts exploded view |
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PVG 120 sectional view |
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Safety in application |
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Control system example................................................................................................................................................................ |
8 |
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Examples of wiring block diagram..................................................................................................................................... |
10 |
Identification |
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Identification ................................................................................................................................................................................... |
12 |
Installation |
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Installation and plug orientation.............................................................................................................................................. |
13 |
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Connection, PVP, Pump Side Module..................................................................................................................................... |
13 |
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Oil flow direction............................................................................................................................................................................ |
14 |
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Tightening Torques....................................................................................................................................................................... |
14 |
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PVM, Lever Positions..................................................................................................................................................................... |
16 |
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Setting of max. flow...................................................................................................................................................................... |
16 |
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Pressure Setting.............................................................................................................................................................................. |
17 |
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PVP, LS Relief Valve Pressure Setting................................................................................................................................. |
17 |
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PVB, LS Relief Valve Pressure Setting................................................................................................................................. |
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Option, Oil Flow Direction and Setting of max Flow......................................................................................................... |
18 |
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Installation of PVE.......................................................................................................................................................................... |
18 |
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Bleeding............................................................................................................................................................................................. |
20 |
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PVPE/PVH relief valves................................................................................................................................................................. |
20 |
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PVPH and LS connections........................................................................................................................................................... |
21 |
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PVPE technical data....................................................................................................................................................................... |
21 |
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Connection PVPE............................................................................................................................................................................ |
22 |
PVP |
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PVP, Pump Side Module.............................................................................................................................................................. |
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PVPD, PVPH, PVPE, Accessories for PVP................................................................................................................................. |
25 |
PVLP / PVLA |
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PVLP / PVLA, Shock and Suction Valve Port A/B................................................................................................................. |
27 |
PVBP, PVBR, PVBC, PVBU |
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PVBP, PVBR, PVBC, PVBU Accessories for PVB...................................................................................................................... |
29 |
PVM |
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PVM, Mechanical Activating Module...................................................................................................................................... |
31 |
PVMD and PVH |
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PVMD, Cover for PVM and PVH, Hydraulic Activation...................................................................................................... |
33 |
PVGI |
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PVGI, Interface for PVG 120 and PVG 32................................................................................................................................ |
34 |
PVEH and PVEO |
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PVEH and PVEO, Electrical Activating Module, ON-OFF................................................................................................... |
35 |
PVT |
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PVT, Tank Side Module – Upper Part....................................................................................................................................... |
37 |
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PVT, Tank Side Module – Lower Part....................................................................................................................................... |
39 |
PVAS and PVGI |
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PVGI, Assembly Kit......................................................................................................................................................................... |
41 |
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PVAS, Assembly Kit........................................................................................................................................................................ |
41 |
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Asssembly sequence............................................................................................................................................................... |
41 |
Set of seals |
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Set of Seals ....................................................................................................................................................................................... |
43 |
PVG 120 Modules Selection Chart |
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PVG 120 module selection chart.............................................................................................................................................. |
44 |
Order specification |
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520L0247 • Rev JA • May 2014 |
3 |
Service Manual |
PVG 120 Proportional Valve Group |
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Contents
Ordering of modules for oil flow exceeding 180 l/min [47.6 US gal/min]................................................................. |
48 |
Order Form....................................................................................................................................................................................... |
48 |
Reordering................................................................................................................................................................................... |
49 |
4 |
520L0247 • Rev JA • May 2014 |
Service Manual |
PVG 120 Proportional Valve Group |
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PVG 120 service parts exploded view |
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PVG 120 service parts exploded view |
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10 |
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6 |
V310144.A |
520L0247 • Rev JA • May 2014 |
5 |
Service Manual |
PVG 120 Proportional Valve Group |
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PVG 120 sectional view
X-X
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11 |
12
11
4
pma
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9 2 A |
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B |
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13 |
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T |
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3 |
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LS
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A 7 5 |
1 B 8 |
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P |
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6 5
V310100.A
Legend: |
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1 |
– Main spool |
7 |
– Shock and suction valve PVLP |
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2 |
– Pressure adjustment spool in PVP |
8 |
– Suction valve PVLA |
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3 |
– Shuttle valve |
9 |
– Orifice, closed center PVP; Plug, open center PVP |
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4 |
– Pressure relief valve in PVP |
10 |
– LS connection |
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5 |
– Pressure compensator in PVB |
11 |
– Orifice, open center PVP |
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6 |
– LS pressure relief valve in PVB |
12 |
– Plug, closed center PVP |
6 |
520L0247 • Rev JA • May 2014 |
Service Manual |
PVG 120 Proportional Valve Group |
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All makes and all types of control valves (incl. proportional valves) can fail, thus the necessary protection against the serious consequences of function failure should always be built into the system. For each application an assessment should be made for the consequences of pressure failure and uncontrolled or blocked movements.
To determine the degree of protection that is required to be built into the application, system tools such an FMEA (Failure Mode and Effect Analysis) and Hazard and Risk Analysis can be used.
FMEA – IEC EN 61508
FMEA (Failure Mode and Effect Analysis) is a tool used for analyzing potential risks. This analytical technique is utilized to define, identify, and prioritize the elimination or reduction of known and/or potential failures from a given system before it is released for production. Please refer to IEC FMEA Standard 61508.
Hazard and risk analysis ISO 12100-1 / 14121
This analysis is a tool used in new applications as it will indicate whether there are special safety considerations to be met according to the machine directives EN 13849. Dependent on the determined levels conformity this analysis will detirmine if any extra requirements for the product design, development process, production process or maintenance, i.e. the complete product life cycle.
W Warning
All makes/brands and types of directional control valves – inclusive proportional valves – can fail and cause serious damage. It is therefore important to analyze all aspects of the application.
Because the proportional valves are used in many different operation conditions and applications,
the manufacturer of the application is alone responsible for making the final selection of the products – and assuring that all performance, safety and warning requirements of the application are met.
The process of choosing the control system – and safety levels – is governed by the machine directives
EN 13849 (Safety related requirements for control systems).
520L0247 • Rev JA • May 2014 |
7 |
Service Manual |
PVG 120 Proportional Valve Group |
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Safety in application
Example of a control system for manlift using PVE Fault monitoring input signals and signals from external sensors to ensure the PLUS+1® main controllers correct function of the manlift.
Legend:
1 – Main power supply
2 – Emergency stop/man present switch
3 – HMI/Joystick control
4 – Movement detection sensors
5 – Main controller
6 – PVG control valve
7 – Hydraulic deactivation
8 |
520L0247 • Rev JA • May 2014 |
Service Manual |
PVG 120 Proportional Valve Group |
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Safety in application
Electrical block diagram for the above illustration
W Warning
It is the responsibility of the equipment manufacturer that the control system incorporated in the machine is declared as being in conformity with the relevant machine directives.
PVG 32 – mainly used in system with fixed displacement pumps:
•PVSK, commonly used in crane application - full flow dump
•PVPX, LS dump to tank
PVG 100 – alternative LS dump or pilot supply disconnect:
•PVPP, pilot oil supply shut off
•External cartridge valve connecting LS pressure or main pressure to tank
PVG 120 – pump disconnect / block for variable pumps:
•PVPE, full flow dump for the PVG 120
•External cartridge valve connecting LS pressure to tank
520L0247 • Rev JA • May 2014 |
9 |
Service Manual |
PVG 120 Proportional Valve Group |
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Safety in application
Example of a typical wiring block diagram using PVEH with neutral power off switch and fault monitoring output for hydraulic deactivation.
Emergency |
Man present |
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A |
stop |
switch |
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PVE 1 |
Neutral detection / Supply control |
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PVEH |
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C |
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1) |
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with AMP |
signal |
OFF |
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connector |
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≠ |
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US |
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Delay |
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neutral |
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UDC2 |
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B |
Error |
PVE 2 |
Neutral detection / Supply control |
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PVEH |
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C |
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1) |
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with AMP |
signal |
OFF |
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connector |
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≠ |
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US |
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Delay |
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neutral |
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UDC2 |
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B |
Error |
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E1 |
E2 |
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2) |
Alarm |
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logic |
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Output |
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<![if ! IE]> <![endif]>OR |
3) Memory |
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<![if ! IE]> <![endif]>AND |
high=on |
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low=off |
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Fault detection output |
D |
Hydraulic |
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deactivation |
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P301 318 |
A– Emergency stop / man present switch B– PVE Fault monitoring signals
C– Neutral signal detection. D– Hydraulic deactivation
System Control Logic e.g. PLUS+1® for signal monitoring and triggering signal for deactivation of the hydraulic system.
W Warning
It is the responsibility of the equipment manufacturer that the control system incorporated in the machine is declared as being in conformity with the relevant machine directives.
10 |
520L0247 • Rev JA • May 2014 |
Service Manual |
PVG 120 Proportional Valve Group |
|
|
Safety in application
Example of fault monitoring for deactivation of the hydraulic system with extra fault inputs using the PVE’s with DI (Direction Indication) function.
Emergency |
Man present |
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Stop |
switch |
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PVE 1 |
Neutral detection / Supply control |
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PVEH-DI |
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1) |
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AMP supply |
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signal |
OFF |
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connector |
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≠ |
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US |
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Delay |
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neutral |
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UDC2 |
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Error |
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PVEH-DI |
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AMP connector |
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DI-B |
2) |
Fault detection |
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DI-A |
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3) |
4) |
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DI-B |
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DI-A |
DI |
Output Delay |
Memory |
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Error |
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US |
Logic |
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PVE 2 |
Neutral detection / Supply control |
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PVEH-DI |
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1) |
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AMP supply |
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signal |
OFF |
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connector |
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≠ |
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US |
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Delay |
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neutral |
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UDC2 |
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Error |
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PVEH-DI |
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AMP connector |
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2) |
Fault detection |
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DI-A |
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DI-B |
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3) |
4) |
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DI-A |
DI |
Output Delay |
Memory |
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Error |
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US |
Logic |
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<![if ! IE]> <![endif]>OR |
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<![if ! IE]> <![endif]>AND |
high=on |
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low=off |
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Fault detection output |
Hydraulic |
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deactivation |
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P301 319 |
System Control Logic e.g. PLUS+1® for signal monitoring and triggering signal for deactivation of the hydraulic system.
W Warning
It is the responsibility of the equipment manufacturer that the control system incorporated in the machine is declared as being in conformity with the relevant machine directives.
520L0247 • Rev JA • May 2014 |
11 |
Service Manual |
PVG 120 Proportional Valve Group |
|
|
PVG 120 Identification
PVB
PVM
PVT
PVM
PVP
PVEH |
G |
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P |
PVEO
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MA |
S |
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E |
F |
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C |
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D |
PVH
PVMD |
V310156.A |
C:PVG – number, week and year of installation
D:PVP – pressure setting
E:PVP – number, week, year and day manufacturing, issue and series No.
F:PVB – A-Port, number, week, year and day manufacturing, issue and series No.
G:PVT – week and year of manufacturing
12 |
520L0247 • Rev JA • May 2014 |
Service Manual |
PVG 120 Proportional Valve Group |
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Installation Dimensions
<![endif]>190 [7.48]*
<![if ! IE]><![endif]>100 [3.94]*
* Room for dismantling
60 Nm |
60 Nm |
<![if ! IE]> <![endif]>[7.48]* |
[530 lbf•in] |
[530 lbf•in] |
<![if ! IE]> <![endif]>190 |
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4xM12x18 |
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[4x7/16-14UNCx0.7] |
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<![if ! IE]> <![endif]>105 [4.13] |
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L |
<![if ! IE]> <![endif]>100 [3.94]* |
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V310179.A |
Module of PVB |
1 |
2 |
3 |
4 |
5 |
6 |
7 |
8 |
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L mm |
168 |
235 |
302 |
369 |
436 |
503 |
570 |
637 |
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L in |
6.61 |
9.25 |
11.88 |
14.53 |
17.17 |
19.80 |
22.44 |
25.08 |
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520L0247 • Rev JA • May 2014 |
13 |
Service Manual |
PVG 120 Proportional Valve Group |
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Installation
Mechanical / electrical actuation |
Mechanical / hydraulic actuation |
A P B A
B P
A B
PB PA
P
V310169.A
V310163.A
A P B
A P
A
B B
PB PA
P
V310162.A
V310170.A
Max. tightening torques – Connection Threads Type G (ISO 228/1)
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Max. tightening torques |
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Ports |
PA, PB |
MA |
LS, LX, PP |
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Sealing thread |
G 1/4 |
G 1/4 |
G 3/8 |
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With steel washer |
35 N•m [310 lbf·in] |
40 N•m [350 lbf·in] |
60 N•m [530 lbf·in] |
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With cooper washer |
30 N•m [270 lbf·in] |
20 N•m [180 lbf·in] |
35 N•m [310 lbf·in] |
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With aluminium washer |
30 N•m [270 lbf.in] |
30 N•m [270 lbf.in] |
40 N•m [350 lbf·in] |
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With cutting edge |
35 N•m [310 lbf.in] |
40 N•m [350 lbf.in] |
60 N•m [530 lbf·in] |
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14 |
520L0247 • Rev JA • May 2014 |
Service Manual |
PVG 120 Proportional Valve Group |
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Installation |
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Max. tightening torques – Mounting Threads in SAE J 518c Flanges |
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Port |
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Size |
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Threads |
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Tightening torque |
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P |
|
1 in |
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M12, 18 deep |
|
68 N•m |
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7/16 - 14 UNC 0.7” deep |
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[600 lbf·in] |
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A/B |
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3/4 in |
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M10, 17 deep |
|
45 N•m |
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3/8 - 16 UNC 0.7” deep |
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[400 lbf·in] |
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T |
|
1 in |
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M10, 17 deep |
|
45 N•m |
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3/8 - 16 UNC 0.7” deep |
|
[400 lbf·in] |
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Max. tightening torques – UN and UNF Connection Threads – O-ring Boss Port |
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Max. tightening torques |
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Ports |
P |
A/B |
T |
PA/PB |
MA |
LS, LX, PP |
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Sealing |
1 5/16 in-12 UN |
1 1/16 in-12 UN |
1 5/16 in-12 UN |
½ in-20 UNF |
½ in-20 UNF |
¾ in-20 UNF |
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/Thread |
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O-ring |
160 N•m |
120 N•m |
160 N•m |
30 N•m |
30 N•m |
60 N•m |
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[1410 in•lbs] |
[1060 in•lbs] |
[1410 in•lbs] |
[270 in•lbs] |
[270 in•lbs] |
[530 in•lbs] |
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Ports identification
520L0247 • Rev JA • May 2014 |
15 |
Service Manual |
PVG 120 Proportional Valve Group |
|
|
Installation
Base with an angle of 37.5°
|
19 |
|
.5˚ |
|
19 |
|
.5˚ |
37 |
67 |
.5˚ |
.5˚ |
|
97 |
|
.5˚ |
|
127 |
|
. |
|
5˚ |
|
157 |
|
. |
|
5˚ |
|
187 |
|
. |
|
5˚ |
Base with an angle of 22.5°
19.5˚
22.5˚ |
52 |
|
.5˚ |
19 .5˚
82 .5˚ 112
. 5˚
142
. 5˚
172
. 5˚
V310018.A
V310014.A
Setting of Max. Flow
|
Q max.A |
|
Q max.B |
Q max. |
Q max. |
|
A |
B |
|
|
T |
|
LX |
PP |
|
|
3[0.12] |
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|
Q max.B |
|
- |
8 Nm |
|
|
+ |
|
Q max.A |
- |
[70 lbf in] |
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||
|
+ |
|
10[0.39] |
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V310101.A |
16 |
520L0247 • Rev JA • May 2014 |